Mould



Jan. 20, 1942. T, B. CHACE 2,270,830

MOLD

Original Filed Aug. l2, 1937 5 Sheetsheet l A @om 'M T. B. CHACE Jan. 207

MOLD

Original Filed Aug. l2, 1937 Patented Jan. 20, 1942 MOULD Thomas B. Chace, Winnetka, Ill., assigner to Clad Metals Industries, Inc., Chicago, Ill., a corporation of Illinois Original application August 12, 1937, Serial No.

158,656. Divided and this application December 26, 1939, Serial No. 310,895

7 Claims.

My invention relates, generally, to methods and means for manufacturing composite metal slabs and it has particular relation to improved means for casting a cladding metal onto one or more surfaces of a backing slab and confining the casting metal to the desired welding surfaces. This application is a division of my copending application Serial No. 158,656, filed August 12, 1937, now Patent No. 2,211,922.

The object of my invention, generally stated, is to provide mould means for casting cladding metal on one or more surfaces of a Ibacking slab and retaining or confining the molten cladding metal to the surfaces to be cladded.

Other objects of my invention will, in part, be obvious and in part appear hereinafter.

Accordingly, my invention is disclosed in the embodiments thereof shown in the accompanying drawings, and it comprises the features of construction, combination of elements, and arrangement of parts which will be exemplified as hereinafter set forth, and the scope of the application of which will be indicated in the appended claims.

For a more complete understanding of the nature and scope of my invention, reference may be had to the following detailed description taken in connection with the accompanying drawings, in which: y

Figure 1 is a vertical sectional view of a soaking pit in which a slab of backing metal may be preheated in a flux or slag bath;

Figure 2 shows the surface of the backing slab protected from oxidation by the air by a coating of slag or flux while it is being transferred from the soaking pit to the casting operation;

Figure 3 is a top plan view of a mould construction that may be employed for cladding only one face of a backing slab;

Figure 4 is a modifi-ed form of the mould construction of Figure 3;

Figure 5 shows still another form of mould construction for casting cladding metal onto only one surface of a backing slab;

Figure 6 shows a mould construction similar to that shown in Figure 5 but arranged to cast the cladding metal onto three surfaces of the backing slab; and

Figure 7 shows a modified form of mould construction for cladding two opposite faces of a backing slab- With a view to practicing my invention, a steel backing slab 20, Figure 1, of suitable size is cleaned on the desired welding surfaces, preferably by sand blasting, and then lowered into a molten bath 2| of viscous substance in a suitable container 22 that is heated by any suitable means, such as by gas supplied by. the nozzles 23, to maintain it in the molten state for preheating the backing slab 20. An eye 24 may be threaded into the top of the backing slab 20 to permit it to be picked up by a hook 25 of a crane for lifting into and out of the container 22. As shown at 2l in Figure 2 of the drawings, the surfaces of the backing slab 20 are covered by a vlayer 21 of material forming the bath 2| so that,

during transit and after the slab 2B has been removed from the bath 2|, its surfaces are prevented from contact with the air and are, therefore, notoxidized. The exact chemistry of the bath 2| is dependent on the combinations of metal to be clad and the required preheating temperatures. The required properties are a relatively low melting temperature and a relatively high viscosity at temperatures well above the melting temperature. For instance, for preheating temperatures around 230|)o F, I have found that a mixture of about borax and 20% by weight boric acid is suitable. The fusing temperature and viscosity of the bath 2| may be increased .by adding more borax, silicic acid, or quartz. It may be decreased by increasing the boric acid content. A `base of cullet (broken glass) with boric acid added to decrease the viscosity has been found usable. The bath 2i is in the form of slag or flux. The melting temperature of the bath 2| should be low enough so that, when it is heated to about 2300n F., it does not chill below its fusing temperature when the cold backing slab 20 is lowered into it.

The backing slab 20 is left in the bath 2| of slag or flux until it is thoroughly preheated. The time required is usually about one hour for each inch of thickness of the slab 2|). During preheating the surfaces of the slab 20 are perfectly sealed from the atmosphere by the bath 2| and, on removing it therefrom for transporting it to the casting operation, a layer of the slag or flux forming the bath 2| of about 15 of an inch in thickness clings to its surfaces as indicated at 2l in Figure 2. As a result of numeroustests on slabs preheated in a bath 2| having the correct composition, I have found, on cooling the slab to room temperature, that its surface under the coating 21 is clean and entirely free from oxidation. The layer v27 of slag or flux hardens on cooling below its melting temperature and may be broken off readily when desired. However, during transit of the slab 20 from the bath 2|, the layer 2'| clings to the surface of the slab and will withstand relatively rough handling Without exposing the surface to which cladding metal is to be applied. If the slab 20 is scraped against an object during transit to the casting operation, the layer 2l may become parted but will quickly close before any substantial oxidation can take place. Of course, the heat stored in the preheated slab 2i) will keep the layer 21 viscous for a relatively long time so that it is unnecessary to take special precautions for quick Icasting after the slab 20 has been removed from the bath 2 I,

The cladding metal is generally' of the character that cannot be readily cast in a mould of the open face type. This is particularly true when the composite slab is intended to have a smooth rollable surface after casting and bonding of the facing metal onto the backing slab so that they will not separate on subsequent working. Metals, such as pure copper, and alloys, such as high nickelcopper alloys and coppernickel-Zinc alloys in the molten state, are very susceptible to the occlusion of gases and form a thick dross on the exposedcasting surface. Such metals and alloys should be cast in a vertical mould so that the drossv and unrollable part is formed on the upper end of the composite slab rather than on a rolling side surface.

I have found that other copper alloys, such as silicon-nickel-copper alloys, can be readily cast onto backing slabs in accordance with my invention. The nickel in these alloys is employed to facilitate bonding to the backing slab and the silicon-nickel in combination forms nickel silicides for the purpose of making the copper more refractory so that it has substantially the same compression resistance in rolling or workingv as the steel backing slab. This is of particular im-V portance for copper clad steel that is clad on two or more sides since such composite slabs are often rolled into products such asv I beams, Z bars, and the like on suitably shaped rolls. Such products require diamond,v oval, and other irregular shaped passes' and, of course, it is essential i that the two metals forming the composite slab elongate the same amount for each pass; In order to accomplish this, I vary'the silicon and nickel content of the copper facingalloy to'suit the carbon content ofthe steel. For example, the resistance to compression or force of the rolls with the same compressionrate at 1600 F. for wrought iron of about 0.02% carbon, mild steel of about 0.08% and medium steel of about 0.45% carbon is respectively 14,000, 21,000, and

33,000 pounds per square inch. 'Io secure the 2' same properties in the composite slab so that it rolls as if it were made of a single metal, I use with wrought iron of aboutv 0.02% to 0.04% carbon a copper alloy of approximately 0.25% to 0.50% silicon and 0.60% to 0.75% nickel. For mild steel having a carbon content of from 0.08% to 0.12% I use 0.50% to 0.90% silicon and 1.0% to 1.25% nickel. For medium steel having a carbon content from 0.25% to 0.45% I use approximately 1.2% tov 1.5% silicon and 1.5% to 2.0% nickel. I find that, if the nickel content is kept slightly in excess ofV the silicon content, bonding is greatly facilitated Without requiringv any extended soaking with the copper in the molten state. This also seems to eliminate any hotor cold short ranges in annealing or rolling.

In Figure 3 of the drawings, I have shown" a mould construction that is suitable for vertically castingcladding metall on one surface only. Provision for cladding one surfaceonly of a backing slab 'presents a difficult problem in mould design since it is not easy to hold the highly heated and fluid molten facing metal in contact with the preheated backing slab and confine it to only one surface. The problem differs from ordinary casting in that facing metal usually has to be heated to a relatively high temperature well above its melting point and, since the backing slab is preheated to a high temperature, the facing metal remains molten for a comparatively long period during which it must be confined. Even if it were practical to t the backing slab into,` a mould while both were cold, it would necessitate heating the mould during preheating of the slab which, of course, would shorten the life of the. mould considerably, and then, too, there is the problem of expansion of the slab in the mould during preheating which must be taken into account. The futility of attempting to fit a large preheated slab. of one thousand pounds or over, for example, intoar conventional type mould and sealing the edges so that the molten facing metal is confined to one or. several surfaces only is quite obvious.

With a View toY solving this problem and cladding the backing slab 'lll on one surface l5 only, I weld along the two. sides of this surface comparatively thin steel strips T6.. It willv be observed that these strips 'Hi are, generally aligned with the welding surface4 'l5 so that. they present a continuation thereof. The strips. '1.6 are welded along two vertical sides only of the backing slab 713 since, for casting purposes, it. may be removed from a soakingy pit, for example the molten bath 2l ofFi'gure l, and placedin an upright position on a casting floor. formedv of sand. The sand will then` form the, bottomfof the mould space. The surfaces of the slab 'Nl' and particularly the welding surfaceA 'l5 may be protected from oxidation by a layer l'l of slag or flux, as

' described hereinbefore.

The mouldspace may be completed by a mould member E8 that is generally in the form of a half section of a conventional mould. The. ends vof the mould member E8 are turned inwardly and adapted to be clamped in fluid tight relationship against the steel strips 'i6 by suitable clamp members 'i9' and 30 that may be drawn up and clamped in place by suitable bolts 8| andl 82, as illustrated. The surfaces between the mould member 'i8 and the steel strips '16, and between the clampsy 19 and' 30' and these thin steel strips l' may be lined with asbestos gaskets 33 and 84 to not only seal the mould' but also to keep the mould member T18' and the clamps l0 and 'from welding to the steel' strips T5., In this manner the mould. parts are readily removedy as soon as the facing metal has solidified.

In order to pour the facing metalvr into. the mould space formed between the. surface l5" of the backing slab 'l and the inner surface of the mould member 18, a pouring sprue or spout'85 is provided in the lefthand end ofthe mould member 18, as shown. A gate 8.6,. opening into the mould space is` provided at the bottom of the sprue or spout to permit bottom pouring. It will be noted that the lefthand end of the mould member 'i8I is split to provide a parting line 81 formed between the mould member 'I8 proper and a spacer 88. Since the spacing member 88. readily separates fromk the. remainder of the mould member 'i8 after the facing metal. has solidified in the sprue orv spout-852 and the gate 86', it is.` a relatively simple matter to'remove this solidified metal and prepare the` mould for reuse.

In operation the backing slab 14 may be preheated in a bath of molten slag or flux, as described hereinbefore, until it has reached the desired temperature. It is then picked up by a suitable crane and deposited on the casting floor in an upright position. The mould member 18 with the spacer member 88 are then assembled and clamped to the thin steel strips 16, the clamping being effected from the cold side of the mould member 18, as will be readily understood. The molten facing metal is then poured into the sprue or spout 85 and runs through the gate 86 into the mould space, the bottom of which is formed by the sand of the foundry floor. After the cladding metal has solidified, the bolts 8| and 82 are loosened and the mould member 18 and the spacer 88 are removed. This leaves the cladding metal and the portion thereof that had solidified in the sprue or spout 85 and the gate 86 integral with the backing slab 14. Since the gate 86 is relatively small, it is a simple matter to break oif or cut the portion of the cladding metal that was cast in the sprue or spout 85 and the gate 86. The composite slab is then ready for rolling according to standard steel mill rolling practice.

One great utility of the type of mould construction shown in Figure 3 is that spacers of various thicknesses can be used between the mould member 18 and the steel strips 16 or the backing slab 14 to increase the mould casting space. In other words, a standard width backing slab 14 can be used and the thickness of the backing slab can be varied within a wide range, and, at the same time, the casting space for the Afacing metal may also be varied by suitable spacers to produce the proper relative thickness of facing metal to the thickness of the backing slab. Such an arrangement eliminates the necessity for a large stock of mould sizes since, if the thickness of the composite slab can be readily varied, it can be rolled to comply with width and length variables in the finished product.

In Figure 4 of the drawings I have illustrated another form of mould construction that is suitable for casting cladding metal on one surface 90 of a backing slab 9|. As described hereinbefore, the backing slab 9| may first be preheated in a suitable bath of slag or ux and its surfaces, at least the surface 90, is protected from oxidation by layer 92 of the slag or flux. Prior to the preheating of the backing slab 9|, relatively thin steel angles 93 and 94 are welded to opposite sides of 4the backing slab 9| along the vertical edges of the surface 90 that is to be clad. Another angle 95 is welded in the corner formed by the flanges of the angle 93 to pro-vide a pouring sprue or spout. At the lower end an aperture 96 is provided in one of the flanges of the angle 93 to provide a gate for the molten cladding metal. The mould space formed by the surface 90 and the opposite flanges of the angles 93 and 94 is completed by a plate 91, the edges of which may be clamped to the angles 93 and 94 by suitable C-clamps 98, as shown. A liner 99 of suitable material, such as asbestos, may be provided on the inside surface of the plate 91 to prevent its being welded to the angles 93 and 94, and the cladding metal being welded to it.

In Figure of the drawings, I have illustrated a mould construction that may be readily applied for casting cladding metal on one surface |00 only of a backing slab |0| that may be remotely operated so that it is unnecessary for one to closely approach the preheated backing slab. Prior to cleaning and preheating the backing slab |0 relatively thin steel strips |02 are Welded along the edges of the surface |00. The backing slab |0| is then preheated in a suitable bath of slag or flux and when lifted therefrom and placed on the casting lioor, the layer |03 of slag or flux protects the surface |00 from oxidation.

The backing slab |0| may be positioned within `a suitable frame |04 on the casting floor that is provided for purposes which will presently be apparent. The mould space is formed by juxtaposing the arms |05 and |06 of the mould pieces |01 and |08 with the steel strips |02, as illustrated. The mould pieces |01 and |08 are separated along a parting line |09 and are provided respectively with a tongue and a groove ||2 to prevent leakage of the molten cladding metal. The mould pieces l 01 and |08 are held or clamped together by integrally formed wedge-shaped portions |3 and |4 that intert with the outwardly flared jaws ||5 and ||6 of a head ||1 which is carried by a plunger |8. The plunger |8 forms a part of a suitable hydraulic ram ||9 that may be supplied from any suitable source of uid pressure through a valve |20. By applying fluid pressure to the ram |I9, the head ||1 is forced toward the backing slab |0I and thereby not only holds the mould pieces |01 and |08 in position but also, by virtue of the clamping action between the jaws ||5 and ||6 and the wedgeshaped portions ||3 and ||4, these mould pieces |01 and |08 are maintained in the desired relation.

Along the parting line |09 a pouring sprue or spout |2| may be provided having a gate |22 at the bottom to provide for bottom pouring of the cladding metal. A groove |23 is provided for receiving a suitable valve member, for separating the molten metal in the sprue or spout |2| and the gate |22 from the cladding metal in the mould space. It will be understood that the valve member will be inserted in the groove |23 and that it will be moved downwardly to separate the bottom portions of molten cladding metal when the mould space has been filled therewith.

It will be observed that the hydraulic ram ||9 is mounted on the frame |04. With a view to further providing for facilitating the handling of the mould pieces 01 and |08, heads |24 and |25 mounted on plungers |26 and |21 of additional hydraulic rams |28 and |29, carried by the frame |04, are provided for engaging the opposite sides of these pieces as illustrated. Valves |30 and |3| may be provided for controlling the application of fluid pressure to the hydraulic rams |28 and |29.

Since the relatively thin steel strips |02 may be bent on application thereto of pressure on movement of the mould pieces |01 and |08 by the hydraulic ram ||9, it is desirable that some means be provided for preventing this distortion. For this purpose a generally C-shaped member is provided, the arms |33 and |34 of which are arranged to engage the rear side of the steel strips |02, as shown. The C-shaped member |32 may be carried by a head |35 that is supported on a plunger |36 of a hydraulic ram |31. A valve |38 may be provided for supplying suitable pressure to the ram |31. Suitable strips |39 of asbestos or like material may be disposed along the opposite faces of the steel strips |02 that are engaged by the arms |05 and meuf the mould pieces |07 and it and byl the arms |33 and. |34 of theC-shaped member |32-,to prevent welding taking place. therebetween.

By the provision of the apparatus shown in Figure 5it is possiblev to quickly and easily make upY the mould. for receiving the moltenv cladding metal and at the same time the operator is not directly exposed to the heat of the backing slab ||l,|'.. If desired, the hydraulic. ram units H9, |28.; |29, and |31 may be adjustably mounted the framey |04 so that it is unnecessary to accurately position the backing slab therein.

In Figure 6 of the drawings, I have shown a mould construction, similar to that shown in FigureV 5, but arranged to provide a mould space with three. surfaces of a backing slab Mil, rather than a single surface. As shown, relatively thin steel strips |42 may be welded to the. surface of. the backing slab |ll| that is not to be clad7 prior to preheating and cleaning. When the backing slab lili is deposited on the casting floor, it is provided with the layer M3 of slag or flux for preventing the oxidation of the three welding surfaces..

The mould space is formed in part by the mould sections |61 and |68 and arms thereofA |65 and |06. which are juxtaposed with the steel strips |42. Arms |33 and |34 of a C-shaped member |32 serve to back up the opposite sides of the steel strips |112, as described hereinbefore. Suitable strips |39 of asbestos or the like may be positioned on opposite sides of the steel strips |42 to prevent welding of the mould and clamp arms thereto.

In Figure 7 of the drawings, I have provided aimould construction that permits the cladding of the opposite surfaces |46 and llii of a backing slab |48. Prior to cleaning and preheating relatively thin steel strips M9 are welded to the opposite corners of the backing slab Hi8, as shown. The backing slab M8 is then cleaned and preheated to the desired temperature. When the. backing slab lfl is placed on the casting floor,l its welding surfaces ifi and ill', at least, are covered by the layer |50 of slag or ux to prevent oxidation thereof, as described previously. A mould space is formed with each of the surfaces |46 and ll by the two-piece mould |01v and ld, such as shown in Figure 5 and described hereinbefore. rIhe heads lll carrying the flared jaws and H may be mounted on plungers l5i of hydraulic rams |52 which may be mounted onclamp members |53. The outer ends |55 and |56 of` the clamp members |53 are turned inwardly to back up the sides of the steel strips |49 opposite the arms |35 and of the mould pieces ii'i and IBB. Valves |57 may be provided for controlling the flow of fluid from any suitable pressure source to the hydraulic rams. |52. Strips |39 of asbestos may be provided on opposite sides of the steel strips M9 to prevent welding thereto of the clamping members.

When the mould construction shown in Figure 7- is employed, it is possible to cast in the mould spaces formed with the surfaces |46 and lill the same cladding metal or two different cladding metals may be employed. Moreover, the casting may take place at. different temperatures. For example, the backing slab |48 may be preheated to a temperature of about 2400" F. Stainless steel, which pours at about 300 F., may be cast in one of the mould spaces. for example, the space formed with the surface M5. The backing slab and cladding metal may then be permitted to cool toabout 2250 F., and then a cladding metal of copper or copper alloy may be poured into the mould space formed with the surface Mil.

Since certain further changes may be made. in the foregoing constructions and different ernbodiments of the. invention may be made without departing from the scope thereof, it is intended that all. matter` contained. in the above description and shown in the accompanying drawings shall be interpreted as illustrative and not in a limiting sense.

I claim as my invention:

1. Means for cladding a steel slab with a cuprous facing comprising. a mould member having peripheral sealing surfaces, said surfaces lying in a common vertical plane, a flange adapted to be welded in fluid tight relation to the lateral faces of a slab to be cladded, said flange being adapted to be disposed adjacent the face to be cladded, and means for holding said flange and said sealing surfaces in liquid tight relation tov form a liquid retaining sealV about the face to be cladded.

2. A mould? for cladding a slab with a facing metal comprising a mould section having pe.- ripheralsealing faces lying in substantially a vertical plane, and a peripheral iiange the inner margins of which are adapted to be welded to a slab to be cladded and the outer margins of which lie in a vertical plane, and means for clamping the peripheral sealing faces of the mould section in liquid retaining relation to said outer margins of the peripheral flange.

3. In means for forming acomposite metal slab comprising a body of backing metal having a welding face and a layer of facing metal diffusion welded to said Welding face by casting said facing metal! iny a mould space with said welding face forming one wall of said space, flange means adapted tofbe secured to said body at the margins thereof adjacent said face and in position extending from said body, said ange means providing a clamping face lying in a plane substantially parallel to said welding face, a cooperating mould member adapted to engage said iiange means to form a closure and thereby provide a definite mould space one side of which is formed by said welding face, and clamping means for l holding said flange means and said mould member in liquid retaining relation.

4. In means for forming a composite metal slab comprising a body of backing metal having a welding face and a layer of facing metal diffusion Welded to said welding face by casting said facing metal in a mould space with said Welding face forming one wall of said space, flange means adapted to be secured to said body in position extending therefrom along said face, a mould member adapted to cooperate with said flange means to provide a definite mould space one side of which is formed by said welding face, and fluid pressure operated clamping means positioned on opposite sides of said body and arranged and adapted to engage said mould member and ange means for clamping the same in liquid retaining relation.

5. In means for forming a composite metal slab comprising a body of backing metal having a weldingface and a layer of facing metalv diffusion welded to said Welding face by casting said facing metal in a mould space with said welding face forming one wall of said space, flange means adapted to be secured to said body in position extending therefrom along opposite sides thereof, a two part mould member adapted to cooperate with said flange means to provide with said Welding face adenite mould space, a pouring sprue mould member is recessed to provide at least a part of the mould space.

'I` The combination of claim 3 wherein the flange means comprises relatively thin metal angle strip or strips having one leg welded to the margin of the body adjacent the welding face.

THOMAS B. CHACE. 

